Expanded-Material Ball Construction for Stable Cold-Weather Elasticity
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Solution Overview
Problem
Existing balls, such as footballs, suffer from complex manufacturing processes, surface deterioration, reduced elasticity at low temperatures, and loss of shape stability due to brittleness and water ingress, leading to decreased performance over time.
Innovation Solution
A ball constructed with particles of expanded materials like eTPU, ePEBA, ePA, ePP, or ePS, connected via RF or IR welding, forming a layer or layers with optional coatings, and optionally incorporating a supporting structure for enhanced durability and elasticity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional ball panels and seams are used, then the ball can be manufactured with standard materials, but the surfaces become brittle over time leading to decreased tear strength and shape stability
Solution Approach 1:
The patent changes the material parameters by using expanded thermoplastic materials (eTPU, ePEBA, ePA, ePP, ePS) instead of conventional materials. These expanded materials maintain flexibility and elasticity across temperature ranges, preventing the brittleness that develops in conventional panels over time, thereby maintaining both tear strength and shape stability.
Solution Approach 2:
The patent employs composite material structures combining expanded thermoplastic particles with bonding agents or adhesives. This composite approach creates a unified material system that exhibits superior mechanical properties, including enhanced tear strength and shape stability, while avoiding the brittleness issues of conventional single-material constructions.
2Productivity
If traditional ball constructions are used, then manufacturing processes are established, but the processing cycle is complicated and long
Solution Approach 1:
The patent segments the ball construction into discrete expanded material particles that can be independently processed and then assembled. This segmentation allows for simplified manufacturing where particles are pre-formed and then quickly assembled using bonding agents or adhesives, reducing the overall processing cycle time compared to traditional multi-step construction methods.
Solution Approach 2:
The patent utilizes the unique properties of expanded thermoplastic materials that allow for rapid processing and assembly. The materials can be quickly bonded together using heat or adhesive, significantly reducing manufacturing cycle time while maintaining structural integrity, thus improving productivity without increasing complexity.
3Reliability
If conventional ball materials are used, then the ball can be manufactured with standard processes, but elasticity is lost at low temperatures
Solution Approach 1:
The patent selects expanded thermoplastic materials (eTPU, ePEBA, ePA, ePP, ePS) that have been specifically chosen for their temperature-dependent properties. These materials maintain their elastic properties across a wide temperature range including low temperatures, ensuring consistent ball performance whether used in cold environments or warm conditions, thereby resolving the elasticity loss issue at low temperatures.
4Reliability
If conventional ball constructions are used, then manufacturing is straightforward, but water ingress occurs leading to decreased shape stability
Solution Approach 1:
The patent uses composite material constructions with expanded thermoplastic particles bonded together using bonding agents or adhesives that provide water-resistant joints. This composite structure eliminates the seams and joints that are prone to water ingress in conventional constructions, thereby preventing water penetration while maintaining shape stability.
Solution Approach 2:
The patent employs expanded materials with specific surface properties and bonding characteristics that create water-resistant joints. The material parameters are selected to ensure that the bonds between particles are strong and water-impermeable, preventing water ingress that would otherwise compromise shape stability in conventional ball constructions.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides balls with improved abrasion resistance, tear strength, and consistent elasticity across temperature ranges, maintaining high performance and shape stability without requiring frequent inflation.
Implementation Method 1
The particles are connected to each other by fusing at their surfaces. The particles may be connected, at least partially, by radio frequency welding
Implementation Method 2
The particles may be connected, at least partially, by radio frequency welding and/or infrared welding
Data Source
AI summary
Described are balls, in particular a football, and a method for its manufacture. The ball comprises particles of an expanded material. As examples, the particles are connected, at least partially, to each other by radio frequency welding and/or infrared welding. As examples, the ball has a first layer of the particles of the expanded material, wherein the first layer is provided as an outer shell.